Protective helmet and method of manufacture thereof

ABSTRACT

A protective helmet according to the invention includes an outer shell and a shock-absorbing cap arranged within the shell, the shell being formed by a thin shell. The shell is covered, at least locally, by a panel made of a flexible material, the panel being stretched against the shell and connected thereto at least one seam line along one of its edges. According to the manufacturing method, the outer shell is made, a panel of flexible material is prepared, the outer shell is then covered with the panel by at least one seam between an edge of the panel and the shell, and the inside of the shell is then fitted with the cap.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. §119 of French Patent Application No. 06 07572, filed on Aug. 29, 2006, the disclosure of which is hereby incorporated by reference thereto in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a protective helmet. The invention also relates to a method for manufacturing the protective helmet.

2. Description of Background and Other Information

It is increasingly common to wear a protective helmet during recreational sporting activities, such as inline skating, ice skating, biking, skiing, and the like. As a general rule, helmets of this type have an outer shell made of a thin but rigid material, such as polycarbonate or ABS, and have internally a shock-absorbing cap made of polystyrene, for example. Such helmets are further equipped with a chin strap and, if necessary, a secondary retaining device that extends over the nape of the wearer's neck. Typically, the helmets also have comfort elements such as foam pads, a textile fitting, sometimes referred to as a lining, inside the cap, or the like.

Vents forming ventilation ducts are provided in the area of the outer shell and of the cap to make the helmet more pleasant to wear.

Two techniques are mainly used to make such helmets. In a first technique, the shell and the cap are made separately and then assembled by means of glue or other means to assemble the two components together.

According to a second technique, after the shell is made, it is positioned inside a mold in order to inject a material that will form the cap after expansion and curing.

In both cases, the outer envelope of the helmet is formed by the thin shell.

In the second case, the shell is constituted by a very thin sheet of a PVC type of material having a thickness such that, when it is bare, the shell is not adequately rigid to provide the protection that could be expected from the finished helmet. Generally speaking, the cap is made of expanded polystyrene or of a similar material. Because the cap and the shell are assembled directly in the mold, during the polystyrene expansion phase, this method for manufacturing the helmet is known as the “in-mold” technique.

Helmets are protective accessories that are not directly involved with the user's performance during the sporting activity. Thus, to make the helmet more attractive to buy and use, manufacturers have sought to improve its aesthetic appearance. A first approach was to work on the shape of the outer shell and of the vents of the helmet. Another approach was to add accessories, such as a visor. A further approach involved decorating the outer shell by means of self-adhesives, transfers, silk printing, or painting, for example, so as to imprint a pattern directly on the shell.

Yet another approach was to add an envelope made of a flexible material in order to change the outer aspect of the shell. Such devices are disclosed in the patent documents FR 2 680 305, EP 1 256 285, and EP 1 358 810.

These devices have the common characteristic of being removable and, if necessary, interchangeable. However, their aesthetic effect is not entirely satisfactory because the fastening mechanisms do not allow the envelope to be stretched over the entire covered surface without causing folds to occur.

Furthermore, it can be difficult to position these devices in helmets made using the in-mold technique, because the material that will constitute the outer skin of the helmet, that is, the shell, is relatively fragile when not supported by the cap.

SUMMARY OF THE INVENTION

In view of this state of the art, there is a need for a helmet and a method of manufacture thereof that are improved in that the covering of the shell has a better appearance and, in particular, in that it does not have folds.

The foregoing and other objects which will become apparent from the description are achieved by a decorating method according to the invention, and by a helmet manufactured by implementing the method.

In particular, the invention provides a protective helmet that includes an outer shell and a shock-absorbing cap arranged within the shell, the latter being formed by a thin shell and covered, at least locally, by a panel made of a flexible material, this panel being stretched against the shell and connected thereto by at least one seam line, formed by stitching or other assembly technique, along one of its edges.

In a particular implementation of the invention, the seam line is visible from the outside.

Further, in a particular implementation, the panel includes a plurality of widths, and a seam line at the junction of two widths connects the panel to the shell. Possibly, the widths have a different texture and/or color.

The panel can also be fixed to the shell by a supplemental assembly expedient, such as a strip of glue or other adhesive, for example.

The shell can have openings forming vents for ventilation. In such a case, the panel has cutouts that coincide with the openings.

The flexible material can also be a textile fabric, a band of leather or of any other flexible material.

The invention is also directed to an implementation of a method for manufacturing a helmet having a thin outer shell and an inner shock-absorbing cap, and which includes the following:

-   -   making the outer shell;     -   preparing a panel of flexible material;     -   connecting the outer shell to the panel by means of at least one         seam line;     -   fitting the inside of the shell with the cap.

In a particular embodiment, the cap is made by injection inside the shell, which is already covered by the panel of flexible material.

The protective helmet includes an outer shell and a shock-absorbing cap arranged within the shell, the assembly defining a plane of symmetry, the shell being formed by a thin shell. The shell is covered, at least locally, by a panel made of a flexible material. The panel is stretched against the shell and is connected thereto by at least one seam line along one of its edges.

According to the manufacturing method, the outer shell is made, a panel of flexible material is prepared, the outer shell is connected to the panel by means of at least one seam line along an edge of the panel, and the inside of the shell is fitted with the cap.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood from the description that follows, with reference to the annexed drawings, in which:

FIG. 1 shows the general construction of a helmet according to the invention;

FIG. 2 shows a rear view of a helmet according to a first embodiment of the invention;

FIG. 3 is a side view of the helmet of FIG. 2;

FIG. 4 is a rear view of a helmet according to another embodiment of the invention;

FIG. 5 is a side view of the helmet of FIG. 4;

FIGS. 6 to 9 schematically show various modes of assembly of the panel directly on the surface of the shell;

FIGS. 10 to 14 show various modes for assembling the widths of a panel;

FIGS. 15 to 18 show various modes for mounting the panel in the area of an opening of the shell;

FIGS. 19 to 21 show various modes for mounting the panel along an edge of the shell;

FIG. 22 shows a phase in the manufacturing method of the invention;

FIG. 23 relates to an alternative embodiment of the method.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a helmet 10 including an outer shell 11 and an inner cap 12.

The outer shell is formed by a shell of plastic material, the shell being thin, having a thickness of 1.5 millimeters (mm), or a thickness of about 1.5 mm or less than about 1.5 mm. In particular, the shell can be produced from a flat sheet of polycarbonate or of PVC having a thickness between 0.7 mm and 1.5 mm, or between about 0.7 mm and about 1.5 mm, that has been cut and shaped by thermoforming. The shell can, optionally, have openings, such as the openings 14, 15, 16, and other openings, if necessary or desired, as well as recessed or raised zones, possibly with form-breaking edges, which may or may not correspond to the openings.

The inner cap 12 forms a shock-absorbing layer provided to envelop and protect the user's head. It can be made of expanded polystyrene, for example. It is provided to line the outer shell 11 internally. The outer surface of the cap assumes the inner shape of the shell. In a particular embodiment, the outer surface of the cap has openings that correspond to the openings of the shell so as to generally form vents that facilitate air circulation beneath the cap.

Generally, the shell and the cap have a shape of a part of a sphere, which shape is symmetrical with respect to a vertical median plane demarcating two hemispheres. This plane is parallel to the plane of FIGS. 3 and 5. Hereinafter, the term “longitudinal” will designate a direction parallel to this plane and “transverse” will designate a perpendicular direction, that is, a direction that extends from one hemisphere to the other.

The symmetry of the shell and of the cap in relation to the median plane makes is possible to produce helmets whose left portion is identical, albeit inverted, to the right portion. This is not a limiting characteristic of the invention, and helmets according to the invention can be provided not to have a right-left symmetry.

The cap is made and assembled to the shell by any appropriate means. According to a first technique, the shell and the cap are made separately and then assembled to one another, in an exemplary manner such as by means of glue or by means of a one-sided or double-sided self-adhesive strip, or by means of any other technique.

According to another known technique, a cut and shaped shell is positioned in a mold and material is then injected inside the mold to form the cap. For example, polystyrene pellets and water steam are injected into the mold under pressure so as to cause the expansion of the polystyrene and to form the cap directly against the shell.

Other manufacturing techniques are also within the scope of the invention.

The shell further includes a device for retention on the user's head, and comfort elements, if necessary. For example, these parts can include a chin strap formed with strap portions connected to the cap and which are provided to be fastened together under the user's chin. There can also be an occipital retaining mechanism that may or may not be associated with the chin strap, as well as pads or fittings made of foam or of any other hygienic or comfort material. Such devices are known and are not shown in the drawings.

FIGS. 2 and 3 show a helmet according to a first embodiment of the invention. This helmet has a shell 21 and a cap 22. A panel 23, or yoke, externally covers the shell 21, i.e., it extends around the rear and lower portion of the shell 21. However, the openings 25 and 26, which are located in this zone, are not covered. The panel 23 is made here with two widths 23 a, 23 b that are assembled to one another such that the panel follows the curvature of the shell in the covered zone. The manner of assembly of the panel is described below.

The panel 23 is made of a flexible material such as a skin, a film, or a fabric based on either natural or synthetic fibers. The material can be colored, embroidered, or patterned. It can also be imprinted, silk printed, or painted. The patterns of the panel can be coordinated with the decoration of the shell. The widths can be of the same or of different type with respect to texture and color. In a particular embodiment, the material is extensible, such that it assumes the rounded shape of the shell without making folds. For example, the material can be leather or imitation leather that has the advantage of being flexible and compressible depth-wise, i.e., thickness-wise, which produces a volume effect. Such a material contrasts well with the appearance of the shell itself. Other materials are suitable, such as a textile fabric, especially blue jeans fabric, i.e., denim.

Other manners of construction are also within the scope of the invention. In particular, the panel could cover the entire shell, or it could include more or less than two widths or pieces. Furthermore, one could provide that there are a plurality of panels positioned at various locations of the shell.

FIGS. 4 and 5 show a helmet 30 according to another embodiment of the invention. The shell 31 of the helmet is covered by a panel 33 that covers the upper portion of the shell, leaving the front and rear portions uncovered.

The panel here is formed of five widths, or pieces, including widths or pieces 33 a, 33 b, 33 c, 33 d that are shown in the drawings. As described above, the pieces are assembled so that the panel assumes the rounded shape of the shell without forming folds. The panel is cut in the area of the vents of the helmet so as not to hinder air circulation between the outside and the inside.

The material of the panel 33 is the same as that described for the previous helmet. As in the preceding case, the panel can cover the cap in a different manner, and it can have a more or less substantial number of pieces.

A panel generally includes two transverse edges that extend from one hemisphere of the shell to the other, as well as connecting edges between these transverse edges.

According to a characteristic of the invention, the panel is assembled to the shell by at least one seam, such as stitching, made along an edge. According to a particular implementation of the invention, the edge involved is a transverse edge of the panel. This edge is sewn to the shell in its surface or along one of its own edges. The panel can be sewn or glued to the shell at the other transverse edge, as well as in the area of the vents, or the edge of the panel can be folded over itself and sewn before being glued on the shell, as described below.

Other seams can also be made between the various widths of a panel, by connecting or without connecting the shell and the panel in this zone.

Because the shell is thin, the seams can be made easily, for example by means of a conventional sewing machine such as those used in shoe-making. A material such as polycarbonate or ABS can be easily perforated with a needle and lends itself well to stitch assembly.

The seams closely keep the panel on the shell. They maintain a long-lasting tension in the panel, which prevents folds from forming. The seams provide an assembly that withstands outside attacks, especially impacts or tears. Moreover, the seams form lines on the surface of the shell, and they leave on the panel a raised imprint that brings out its texture and contribute to making the appearance of the helmet more attractive. Once stitched, the panel is irremovable, that is, it cannot be disassembled without being damaged, unless such an operation is performed by an experienced person.

The helmet can have zones where the wall of the shell forms a recess, and the panel naturally tends to move away from the wall of the shell in these zones. These zones can be glued prior to applying the panel on the shell, and pressure can be applied on the panel so that it stretches locally and assumes the shape of the shell in these recessed zones.

FIGS. 6 to 21 show various methods for mounting the connection between the panel and the shell. More particularly, they show the assembly of the panel 23 on the shell 21 of the first embodiment. For an easier understanding of the invention, the reference numerals of FIGS. 2 and 3 are used again in FIGS. 6 to 21 to designate the shell and the various widths of the panel.

FIGS. 6 to 9 show various methods for mounting the panel directly on the surface of the shell.

According to FIG. 6, the transverse upper edge of the width 23 b, or piece, forms a cuff, the flap of which is sewn to the shell 22 at a seam line 40. The seam line is not visible in this case.

According to FIG. 7, the edge of the width 23 b forms a cuff; the assembly is then sewn at a seam line 41.

According to FIG. 8, the flap of the cuff is sewn to the shell 22 along a first seam line 43; the assembly is then sewn to the shell at a second seam line 44.

According to FIG. 9, a cuff is formed and sewn at a seam line 45; the assembly is then glued to the shell by means of a strip of glue 46. In this case, the seam is visible, but it does not connect the panel to the shell. The other transverse edge is then arranged to be the one sewn to the shell.

FIGS. 10 to 14 show the junction between the two widths 23 a and 23 b. According to FIG. 10, the two widths are sewn edge to edge at a seam line 48 that is positioned with the flaps on the side of the shell.

According to FIG. 11, a cuff is formed at the edge of the width 23 b, which is sewn to the width 23 a at a seam line 49.

FIG. 12 shows the same type of assembly, but the seam line 50 also connects the shell.

According to FIG. 13, the two widths are sewn edge to edge at a seam line 52, and then each flap is sewn at a seam line 53, 54.

According to FIG. 14, the two widths are sewn edge to edge at a seam line 55, and then each width edge is sewn to the shell at a seam line 56, 57 that is visible from the outside.

FIGS. 15 to 18 show the mounting of the width 23 a in the area of the opening 26 of a vent.

According to FIG. 15, the width is cut and the edges of the cutout are folded back through the opening 26 inside the shell. They are sewn at a seam line 60.

According to FIG. 16, the edges of the cutout are passed through the cutout and are glued inside the shell by means of a strip of glue 61.

According to FIG. 17, the edges of the cutout are folded back on the panel itself, and the assembly is sewn on the shell at a seam line 62.

According to FIG. 18, the panel is cut flush with the opening 26, and its edges are glued by a strip of glue 63.

FIGS. 19 to 22 show the mounting of an edge of the panel along an edge of the shell 22.

According to FIG. 19, the edge of the panel 23 is folded back and glued inside the shell 22 by a strip of glue 64.

According to FIG. 20, rather then being glued, the edge is sewn at a seam line 65 that extends through the assembly and is visible from the outside.

According to FIG. 21, the flap of the panel 23 is folded back between the panel and the shell, and the assembly is sewn at a seam line 66.

These various methods of assembly make it possible to cover the shell with the panel, and to stretch the latter without forming folds. The panel is then completely integrated into the structure of the helmet in terms of aesthetics. The method of assembly is selected as a function of the material used to make the panel, of the shape of the pieces/widths, and also of the desired aesthetic effect. Other methods of assembly are also within the scope of the invention.

According to the manufacturing method of the invention, the shell of the helmet and the panel are initially made and assembled, and then the shell is fitted with the cap using one of the previously mentioned techniques.

FIG. 22 shows this part of the method. First, a bare shell 68 is prepared, cut and shaped by any appropriate technique, such as thermoforming in particular. The shell is given its final shape with, if necessary, the openings for ventilation and the shape-breaking ridges for the recessed or raised zones.

Next, the panel 69 is prepared, with its various pieces joined together, if necessary. The openings for the vents can be made before or after assembly of the panel to the shell.

The panel is then assembled to the shell along its various edges. A seam is made on at least one edge of the panel. A sewing or gluing technique is used on the other edges, as described above in relation to the preceding drawing figures. It is the same thing in the area of the openings.

Next, the shell is fitted with the cap. According to a first technique, the cap is made separately and assembled inside the shell with glue or an adhesive, or by any other appropriate means.

According to a second technique, the shell is positioned in an injection mold, and a material is injected in the mold to form the cap. By means of this technique, the wall of the shell is pressed against the mold imprint, including in the zones that are covered by the panel. This ensures that the panel is applied against the shell, including in the recessed zones. Possibly, one can provide to spread glue in these zones during assembly of the panel in order to reinforce adherence with the shell. One can also provide to insert a film of heat meltable glue between the panel and the shell at the time of assembly. During injection, the film of glue melts and contributes to the adherence of the panel to the shell. The same press and mold can be used to carry out the injection for helmets whose shell is covered and helmets whose shell is bare. Indeed, the presence of the panel does not significantly change the positioning of the shell in the mold.

For the first fitting technique, these operations can be carried out in a press, where the shell covered with the panel is compressed and, if necessary, heated.

When the cap is positioned by injection inside the shell, it confines all of the flaps that are folded inside the shell, including in the zones where the flaps would not have been connected to the shell.

FIG. 23 shows another embodiment of the invention. First, the panel 70 is prepared and then assembled on the sheet 71 of thermoforming material from which the shell is made by means, for example, of two seam lines 72 and 73 along each transverse edge of the panel. The other edges are glued, or are provided to be folded back inside the shell after it has been shaped. Next, the sheet covered with the panel is shaped, and then cut to form the covered shell. The heat required for shaping the sheet can be used, for example, to melt a glue film between the panel and the shell which reinforce the adherence between the shell and the panel.

This disclosure is given by way of example, and other embodiments of the invention can be applied without leaving the scope thereof.

In particular, the helmet can be equipped with a retaining device and comfort elements.

The panel could also be made of two or more separate portions. 

1. A protective helmet comprising: a thin outer shell; a shock-absorbing cap arranged within the shell; the shell being at least partially covered by a panel of flexible material; the panel being stretched against the shell and assembled to the shell by means of at least one seam along at least one edge of the panel.
 2. A protective helmet according to claim 1, wherein: the seam is visible from outside the helmet.
 3. A protective helmet according claim 2, wherein: the panel is formed from a plurality of pieces.
 4. A protective helmet according to claim 3, wherein: at a junction of two of said plurality of pieces a seam line connects the panel to the shell.
 5. A protective helmet according to claim 3, wherein: at least two of the pieces of the panel have different textures and/or different colors.
 6. A protective helmet according to claim 1, wherein: at least a second edge of the panel is assembled to the shell by means of at least at least one seam.
 7. A protective helmet according to claim 1, wherein: at least a second edge of the panel is assembled to the shell by means of at least a strip of glue.
 8. A protective helmet according to claim 1, wherein: the shell has ventilation openings; and the panel has cutouts coinciding with said openings.
 9. A protective helmet according to claim 1, wherein: the flexible material of the panel is a textile fabric.
 10. A protective helmet comprising: an outer shell formed from a flat sheet having a thickness between 0.7 mm and 1.5 mm, or between about 0.7 mm and about 1.5 mm; a shock-absorbing cap arranged within the shell; the shell being at least partially covered by a panel of flexible material; the panel being stretched against the shell and assembled to the shell by means of at least one seam along at least one edge of the panel.
 11. A protective helmet according to claim 10, wherein: the seam is visible from outside the helmet.
 12. A protective helmet according to claim 10, wherein: the panel is formed from a plurality of pieces.
 13. A protective helmet according to claim 12, wherein: at a junction of two of said plurality of pieces a seam line connects the panel to the shell.
 14. A protective helmet according to claim 12, wherein: at least two of the pieces of the panel have different textures and/or different colors.
 15. A protective helmet according to claim 10, wherein: at least a second edge of the panel is assembled to the shell by means of at least at least one seam.
 16. A protective helmet according to claim 10, wherein: at least a second edge of the panel is assembled to the shell by means of at least a strip of glue.
 17. A protective helmet according to claim 10, wherein: the shell has ventilation openings; and the panel has cutouts coinciding with said openings.
 18. A protective helmet according to claim 10, wherein: the flexible material of the panel is a textile fabric.
 19. A method for manufacturing a helmet having a thin outer shell and an inner shock-absorbing cap, said method comprising: making the outer shell; making a panel of flexible material; connecting the outer shell with the panel by means of at least one seam along at least one edge of the panel; fitting an inside of the shell with the cap.
 20. A method according to claim 19, further comprising: making the cap by injection of material inside the shell, the shell having been covered by the panel prior to making the cap. 